An accurate evaluation for the activity of nano-sized electrocatalysts by a thin-film rotating disk electrode: Oxygen reduction on Pt/C

Design and Impact: Navigating the Electrochemical Characterization Methods for Supported Catalysts

This review will investigate the impact of electrochemical characterization method design choices on intrinsic catalyst activity measurements by predominantly using the oxygen reduction reaction (ORR) on supported catalysts as a model reaction. The wider use of hydrogen for transportation or electrical grid stabilization requires improvements in proton exchange membrane fuel cell (PEMFC) performance. One of the areas for improvement is the (ORR) catalyst efficiency and durability. Research and development of the traditional platinum-based catalysts have commonly been performed using rotating disk electrodes (RDE), rotating ring disk electrodes (RRDE), and membrane electrode assemblies (MEAs). However, the mass transport conditions of RDE and RRDE limit their usefulness in characterizing supported catalysts at high current densities, and MEA characterizations can be complex, lengthy, and costly. Ultramicroelectrode with a catalyst-filled cavity addresses some of these problems, but with limited success. Due to the properties discussed in this review, the recent floating electrode (FE) and the gas diffusion electrode (GDE) methods offer additional capabilities in the electrochemical characterization process. With the FE technique, the intrinsic activity of catalysts for ORR can be investigated, leading to a better understanding of the ORR mechanism through more reliable experimental data from application-relevant high-mass transport conditions. The GDEs are helpful bridging tools between RDE and MEA experiments, simplifying the fuel cell and electrolyzer manufacturing and operating optimization process.

Indispensable Nafion Ionomer for High-Efficiency and Stable Oxygen Evolution Reaction in Alkaline Media

Addressing the challenge of sluggish kinetics and limited stability in alkaline oxygen evolution reactions, recent exploration of novel electrochemical catalysts offers improved prospects. To expedite the assessment of these catalysts, a half-cell rotating disk electrode is often favored for its simplicity. However, the actual catalyst performance strongly depends on the fabricated catalyst layers, which encounter mass transport overpotentials. We systematically investigate the role and sequence of electrode drop-casting methods onto a glassy carbon electrode regarding the efficiency of the oxygen evolution reaction. The catalyst layer without Nafion experiences nearly 50% activity loss post stability test, while those with Nafion exhibit less than 5% activity loss. Additionally, the sequence of application of the catalyst and Nafion also shows a significant effect on catalyst stability. The catalyst activity increases by roughly 20% after the stability test when the catalyst layer is coated first with an ionomer layer, followed by drop-casting the catalysts. Based on the half-cell results, the Nafion ionomer not only acts as a binder in the catalyst layer but also enhances the interfacial interaction between the catalyst and electrolyte, promoting performance and stability. This study provides new insights into the efficient and accurate evaluation of electrocatalyst performance and stability as well as the role of Nafion ionomer in the catalyst layer.

Platinum nanosheets synthesized via topotactic reduction of single-layer platinum oxide nanosheets for electrocatalysis

Increasing the performance of Pt-based electrocatalysts for the oxygen reduction reaction (ORR) is essential for the widespread commercialization of polymer electrolyte fuel cells. Here we show the synthesis of double-layer Pt nanosheets with a thickness of 0.5 nm via the topotactic reduction of 0.9 nm-thick single-layer PtO_x nanosheets, which are exfoliated from a layered platinic acid (H_yPtO_x). The ORR activity of the Pt nanosheets is two times greater than that of conventionally used state-of-the-art 3 nm-sized Pt nanoparticles, which is attributed to their large electrochemically active surface area (124 m² g^-1). These Pt nanosheets show excellent potential in reducing the amount of Pt used by enhancing its ORR activity. Our results unveil strategies for designing advanced catalysts that are considerably superior to traditional nanoparticle systems, allowing Pt catalysts to operate at their full potential in areas such as fuel cells, rechargeable metal-air batteries, and fine chemical production.

Selection of oxygen reduction catalysts for secondary tri-electrode zinc-air batteries

Oxygen reduction reaction (ORR) electrocatalysts, which are highly efficient, low-cost, yet durable, are important for secondary Zn–air cell applications. ORR activities of single and mixed metal oxide and carbon electrocatalysts were studied using rotating disc electrode (RDE) measurements, Tafel slope and Koutecky–Levich plots. It was found that MnO_x combined with XC-72R demonstrated high ORR activity and good stability—up to 100 mA cm⁻². The performance of the selected ORR electrode and a previously optimised oxygen evolution reaction (OER) electrode was thereafter tested in a custom-built secondary Zn–air cell in a tri-electrode configuration, and the effects of current density, electrolyte molarity, temperature, and oxygen purity on the performance of the ORR and OER electrode were investigated. Finally, the durability of the secondary Zn–air system was assessed, demonstrating energy efficiencies of 58–61% at 20 mA cm⁻² over 40 h in 4 M NaOH + 0.3 M ZnO at 333 K.

Carbon-Supported Pt-SnO2 Catalysts for Oxygen Reduction Reaction over a Wide Temperature Range: Rotating Disk Electrode Study

Pt/C and Pt/x-SnO2/C catalysts (where x is mass content of SnO2) were synthesized using a polyol method. Their kinetic properties towards oxygen reduction reaction were studied by a rotating disk electrode (RDE) technique in a temperature range from 1 to 50 °C. The SnO2 content of catalyst samples was 5 and 10 wt.%. A quick evaluation of the catalyst activity, electrochemical behavior and average number of transferred electrons were performed using the RDE technique. It has been shown that the use of x-SnO2 (through modification of the carbon support) in a binary system together with Pt does not reduce the catalyst activity in the temperature range of 1–30 °C. The temperature rising up to 50 °C resulted in composite catalyst activity reduction at about 30%.

Prudent Practices in ex situ Durability Analysis Using Cyclic Voltammetry for Platinum-based Electrocatalysts

Platinum (Pt)-based electrocatalysts are at the vanguard of research initiatives to meet activity and durability targets for promoting large-scale adoption of fuel cell vehicles. Ex situ characterization of electrocatalyst activity and durability using cyclic voltammetry (CV) has a steep learning curve. Thus, many researchers who do not receive formal training in electrochemistry are left unsure how to proceed. Herein, we identify and compile prudent practices for reliable assessment of ECSA values with examples from our research on nanoscale catalytic films formed by the self-terminating electrodeposition of Pt. Starting with a conceptual framework to understand typical features in the CV of reversible redox couples, we present prudent practices in acquiring CV data aimed at nonelectrochemists. We then highlight specific features related to ECSA computation from Pt CV. Finally, we suggest safeguards that help avoid missteps and achieve repeatable results while conducting ex situ durability tests that extend over days.

The CO Tolerance of Pt/C and Pt-Ru/C Electrocatalysts in a High-Temperature Electrochemical Cell Used for Hydrogen Separation

This paper describes an experimental evaluation and comparison of Pt/C and Pt-Ru/C electrocatalysts for high-temperature (100–160 °C) electrochemical hydrogen separators, for the purpose of mitigating CO poisoning. The performances of both Pt/C and Pt-Ru/C (Pt:Ru atomic ratio 1:1) were investigated and compared under pure hydrogen and a H₂/CO gas mixture at various temperatures. The electrochemically active surface area (ECSA), determined from cyclic voltammetry, was used as the basis for a method to evaluate the performances of the two catalysts. Both CO stripping and the underpotential deposition of hydrogen were used to evaluate the electrochemical surface area. When the H₂/CO gas mixture was used, there was a complex overlap of mechanisms, and therefore CO peak could not be used to evaluate the ECSA. Hence, the hydrogen peaks that resulted after the CO was removed from the Pt surface were used to evaluate the active surface area instead of the CO peaks. Results revealed that Pt-Ru/C was more tolerant to CO, since the overlapping reaction mechanism between H₂ and CO was suppressed when Ru was introduced to the catalyst. SEM images of the catalysts before and after heat treatment indicated that particle agglomeration occurs upon exposure to high temperatures (>100 °C)

Effect of porosity and active area on the assessment of catalytic activity of non-precious metal electrocatalyst for oxygen reduction

We describe a method to study porous thin-films deposited onto rotating disc electrodes (RDE) applied to non-platinum group electrocatalyst obtained by pyrolysis of iron phthalocyanine and carbon, FePc/C. The electroactive area and porous properties of the thin film electrodes were obtained using electrochemical impedance spectroscopy under the framework of de Levie impedance model. The electrocatalytic activity of different electrodes was correlated to the total electroactive area (A_p) and the penetration ratio parameter through the film under ac current. The cylindrical pore model was extended to the RDE boundary conditions and derived in a Koutecky-Levich type expression that allowed to separate the effect of the electroactive area and structural properties. The resulting specific electrocatalytic activity of FePc/C heat treated at different temperatures was correlated to FePc surface concentration.

Electrocatalyst Performance at the Gas/Electrolyte Interface under High-Mass-Transport Conditions: Optimization of the "Floating Electrode" Method

The thin-film rotating disk electrode (TF-RDE) is a well-developed, conventional ex situ electrochemical method that is limited by poor mass transport in the dissolved phase and hence can only measure the kinetic response for Pt-based catalysts in a narrow overpotential range. Thus, the applicability of TF-RDE results in assessing how catalysts perform in fuel cells has been questioned. To address this problem, we use the floating electrode (FE) technique, which can facilitate high-mass transport to a catalyst layer composed of an ultralow loading of catalyst (1-15 μg_Pt cm_geo^-2) at the gas/electrolyte interface. In this paper, the aspects that have critical effects on the performance of the FE system are measured and parametrized. We find that, in order to obtain reproducible results with high performance, the following factors need to be taken into account: system cleanliness, break-in procedure, hydrophobic agent, ionomer type, and the measurements of catalyst surface area and loading. For some of these parameters, we examined a range of different approaches/materials and determined the optimum configuration. We find that the gas permeability of the hydrophobic agent is an important factor for improving the hydrogen oxidation reaction (HOR) and oxygen reduction reaction (ORR) performance. We provide evidence that the suppression of the HOR and ORR introduced by the Nafion ionomers is more than a local mass transport barrier but that a mechanism involving the adsorption of the sulfonate on Pt also plays a significant role. The work provides intriguing insights into how to manufacture and optimize electrocatalyst systems that must function at the gas/electrolyte interface.

Recent advances in two-dimensional materials and their nanocomposites in sustainable energy conversion applications

Two-dimensional (2D) materials have a wide platform in research and expanding nano- and atomic-level applications. This study is motivated by the well-established 2D catalysts, which demonstrate high efficiency, selectivity and sustainability exceeding that of classical noble metal catalysts for the oxygen reduction reaction (ORR), oxygen evolution reaction (OER), and/or hydrogen evolution reaction (HER). Nowadays, the hydrogen evolution reaction (HER) in water electrolysis is crucial for the cost-efficient production of a pure hydrogen fuel. We will also discuss another important point related to electrochemical carbon dioxide and nitrogen reduction (ECR and N2RR) in detail. In this review, we mainly focused on the recent progress in the fuel cell technology based on 2D materials, including graphene, transition metal dichalcogenides, black phosphorus, MXenes, metal-organic frameworks, and metal oxide nanosheets. First, the basic attributes of the 2D materials were described, and their fuel cell mechanisms were also summarized. Finally, some effective methods for enhancing the performance of the fuel cells based on 2D materials were also discussed, and the opportunities and challenges of 2D material-based fuel cells at the commercial level were also provided. This review can provide new avenues for 2D materials with properties suitable for fuel cell technology development and related fields.

Molybdenum Doping Augments Platinum-Copper Oxygen Reduction Electrocatalyst

Improving the efficiency of Pt-based oxygen reduction reaction (ORR) catalysts while also reducing costs remains an important challenge in energy research. To this end, we synthesized highly stable and active carbon-supported Mo-doped PtCu (Mo-PtCu/C) nanoparticles (NPs) from readily available precursors in a facile one-pot reaction. Mo-PtCu/C displays two-to-fourfold-higher ORR half-cell kinetics than reference PtCu/C and Pt/C materials, a trend that was confirmed in proof-of-concept experiments by using a H₂ /O₂ microlaminar fuel cell. This Mo-induced activity increase mirrors observations for Mo-PtNi/C NPs and possibly suggests an emerging trend. Electrochemical-accelerated stability tests revealed that dealloying was greatly reduced in Mo-PtCu/C in contrast to the binary alloys PtCu/C and PtMo/C. Supporting DFT studies suggested that the exceptional stability of Mo-PtCu could be attributed to oxidative resistance of the Mo-doped atoms. Furthermore, our calculations revealed that oxygen could induce segregation of Mo to the catalytic surface, at which it effected beneficial changes to the surface oxygen adsorption energetics in the context of the Sabatier principle.

Perovskite Electrocatalysts for the Oxygen Reduction Reaction in Alkaline Media

Oxygen reduction is considered a key reaction for electrochemical energy conversion but slow kinetics hamper application in fuel cells and metal-air batteries. In this review, the prospect of perovskite oxides for the oxygen reduction reaction (ORR) in alkaline media is reviewed with respect to fundamental insight into activity and possible mechanisms. For gaining these insights, special emphasis is placed on highly crystalline perovskite films that have only recently become available for electrochemical interrogation. The prospects for applications are evaluated based on recent progress in the synthesis of perovskite nanoparticles. The review concludes with the current understanding of oxygen reduction on perovskite oxides and a perspective on opportunities for future fundamental and applied research.

Elucidating the degradation mechanism of the cathode catalyst of PEFCs by a combination of electrochemical methods and X-ray fluorescence spectroscopy

In this study, we report a methodology which enables the determination of the degradation mechanisms responsible for catalyst deterioration under different accelerated stress protocols (ASPs) by combining measurements of the electrochemical surface area (ECSA) and Pt content (by X-ray fluorescence).

Physical Chemistry Research Toward Proton Exchange Membrane Fuel Cell Advancement

Hydrogen fuel cells, the most common type of which are proton exchange membrane fuel cells (PEMFCs), are on a rapid path to commercialization. We credit physical chemistry research in oxygen reduction electrocatalysis and theory with significant breakthroughs, enabling more cost-effective fuel cells. However, most of the physical chemistry has been restricted to studies of platinum and related alloys. More work is needed to better understand electrocatalysts generally in terms of properties and characterization. While the advent of such highly active catalysts will enable smaller, less expensive, and more powerful stacks, they will require better understanding and a complete restructuring of the diffusion media in PEMFCs to facilitate faster transport of the reactants (O2) and products (H2O). Even Ohmic losses between materials become more important at high power. Such lessons from PEMFC research are relevant to other electrochemical conversion systems, including Li-air batteries and flow batteries.